A new type of electric fusion joint based on magnetic induction eddy current heating

Abstract

The application discloses a novel electric fusion joint based on magnetic induction eddy current heating, which comprises an electric fusion sleeve body, a bolt, a spiral coil, a honeycomb-shaped magnetic conductive metal net, an observation port and a pipe to be welded. The spiral coil is sleeved outside the electric fusion sleeve body and connected with an external alternating power supply; the honeycomb-shaped magnetic conductive metal net is embedded inside the electric fusion sleeve body; the pipe to be welded is arranged in the honeycomb-shaped magnetic conductive metal net; and the observation port is arranged on the electric fusion sleeve body. The electric fusion joint further comprises a monitoring and adjusting system, wherein the monitoring system comprises an infrared CCD camera and a controller; the infrared CCD camera is used for acquiring temperature data and temperature images in a welding process; the controller receives data sent by the infrared CCD camera and processes the data to adjust the frequency of an alternating magnetic field generated by the spiral coil, so that the heat generated by the honeycomb-shaped magnetic conductive metal net is changed. The electric fusion joint has high heating efficiency, high speed and a self-regulating welding temperature field.

Description

Technical Field

[0001] This invention relates to the field of polyethylene pipe welding, and in particular to a novel electrofusion joint using crucian carp magnetic induction eddy current heating. Background Technology

[0002] The existing polyethylene electrofusion sleeve includes an electrofusion sleeve body, a limiting pin, a heating wire, and terminals. The heating wire is arranged in a spiral pattern on the inner wall of the electrofusion sleeve. The working principle of polyethylene pipe electrofusion welding is as follows: First, the end of the pipe to be welded is inserted into the electrofusion sleeve. A welding voltage is applied to the terminals at both ends of the electrofusion sleeve using an electrofusion welding machine, energizing the heating wire. The energized heating wire heats up, melting the polyethylene material, and then the electrofusion sleeve and the pipe to be welded are fused together to form an electrofusion joint with a certain strength.

[0003] The existing electrofusion sleeve and electrofusion welding system still have the following problems: deformation caused by uneven temperature distribution during the welding process leads to poor welding quality, short service life and welding defects in the electrofusion joint, which in turn leads to gas leakage; the existing electrofusion welding system is mainly controlled by the electrofusion welding machine, which does not have a visualization function, has a weak monitoring effect on the welding process, and stores less welding data, which increases the workload of troubleshooting failed electrofusion joints. Summary of the Invention

[0004] The purpose of this invention is to provide a novel electrofusion joint based on magnetic induction eddy current heating, which can solve one or more of the above-mentioned technical problems.

[0005] To achieve the above objectives, the technical solution proposed by this invention is as follows:

[0006] A novel electrofusion joint based on magnetic induction eddy current heating includes an electrofusion sleeve body, bolts, a spiral coil, a honeycomb magnetic conductive metal mesh, an observation port, and a pipe fitting to be welded;

[0007] The spiral coil is sleeved outside the main body of the electrofusion sleeve, and the spiral coil is connected to an external alternating power supply;

[0008] A honeycomb-shaped magnetically conductive metal mesh is embedded inside the main body of the electrofusion sleeve; the pipe fitting to be welded passes through the honeycomb-shaped magnetically conductive metal mesh.

[0009] An observation port is provided on the electrofusion sleeve body, and the observation port extends from outside the electrofusion sleeve body into the electrofusion sleeve body.

[0010] Furthermore: the main body of the electrofusion sleeve includes an upper electrofusion sleeve and a lower electrofusion sleeve; the upper electrofusion sleeve extends outward and is provided with an upper connecting lug, and the upper connecting lug is provided with a first threaded through hole; the lower electrofusion sleeve extends outward and is provided with an upper connecting lug, and the lower connecting lug is provided with a second threaded through hole; the bolt passes through the first threaded through hole and the second threaded through hole to fasten the upper electrofusion sleeve and the lower electrofusion sleeve to the outside of the pipe to be welded.

[0011] Furthermore: the outer surface of the upper electrofusion sleeve is provided with a first external thread groove, the outer surface of the lower electrofusion sleeve is provided with a second external thread groove, and the spiral coil is wound along the first external thread groove and the second external thread groove.

[0012] Furthermore: the honeycomb magnetic metal mesh includes an upper honeycomb magnetic metal mesh and a lower honeycomb magnetic metal mesh; the upper honeycomb magnetic metal mesh is fixedly installed inside the upper electrofusion sleeve; the lower honeycomb magnetic metal mesh is fixedly installed inside the lower electrofusion sleeve.

[0013] Furthermore, the thickness of the honeycomb magnetic metal mesh ranges from 0.5 to 2.0 mm.

[0014] Furthermore, the spiral coil has 10 to 20 turns, and the pitch between the turns is 5 to 10 mm.

[0015] Furthermore, it also includes a monitoring and adjustment system, which includes an infrared CCD camera and a controller; the infrared CCD camera is used to acquire temperature data and temperature images during the welding process and send the data to the controller; the controller is used to receive the data sent by the infrared CCD camera and process the data to adjust the frequency of the alternating magnetic field generated by the helical coil, thereby changing the heat generated by the honeycomb magnetic metal mesh.

[0016] Furthermore, the adjustment method is as follows:

[0017] (1) Set the welding threshold;

[0018] (2) Obtain real-time temperature data and corresponding real-time temperature images during the welding process using an infrared CCD camera;

[0019] (3) Perform image processing on the real-time temperature data and the corresponding real-time temperature image in the step to generate an image matrix, form a projected grayscale image and reconstruct the welding temperature field to obtain the welding temperature field, the current minimum temperature, the maximum temperature and the average temperature.

[0020] (4) Compare the results obtained in the step with the threshold in the step to obtain the temperature adjustment amount ΔT;

[0021] (5) According to the temperature adjustment amount ΔT in the step, adjust the alternating power supply to change the output voltage frequency, thereby changing the frequency of the alternating magnetic field generated in the spiral coil, adjusting the heat generated by the magnetic eddy current effect of the honeycomb magnetic metal mesh, so as to keep the welding temperature stable in real time throughout the welding process to ensure the effective welding of the electrofusion joint.

[0022] The technical effects of this invention are:

[0023] This invention is based on magnetic eddy current effect heating, which has the characteristics of high heating efficiency, fast speed, easy temperature control and easy automation control. It uses a honeycomb-shaped magnetic metal mesh as a heat source, which does not affect the flow of polyethylene material after melting and can make the welding temperature field distribution uniform, reduce the deformation unevenness caused by the uneven welding temperature field, and improve the welding quality of electrofusion joint.

[0024] Furthermore, in this invention, the entire electrofusion welding process is monitored by an infrared CCD camera, and welding temperature field data during the welding process is acquired. The acquired data information is transmitted to the terminal processor, which processes the welding temperature data, displays it visually, and controls the output voltage frequency of the alternating power supply in real time. This changes the frequency of the magnetic field generated by the spiral coil, adjusts the heat generated by the honeycomb magnetic permeable metal mesh due to the magnetic eddy current effect, and achieves self-regulation of the welding temperature field. Attached Figure Description

[0025] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0026] In the attached diagram:

[0027] Figure 1 This is a 3 / 4 cross-sectional structural diagram of the intelligent welding system based on the eddy current effect in this invention;

[0028] Figure 2 This is a 3 / 4 cross-sectional three-dimensional structural diagram of the main body of the electrofusion sleeve in this invention;

[0029] Figure 3 This is a three-dimensional structural diagram of the honeycomb magnetic metal mesh in this invention;

[0030] Figure 4 This is a three-dimensional structural diagram of the helical coil in this invention;

[0031] Figure 5 This is a flowchart illustrating the welding control principle in this invention.

[0032] The above-mentioned figures include the following reference numerals: 1-bolt; 2-spiral coil; 3-upper electrofusion sleeve; 4-lower electrofusion sleeve; 5-pipe to be welded; 6-infrared CCD camera; 7-terminal processor; 8-alternating power supply; 9-honeycomb magnetic metal mesh; 10-observation port; 11-electrofusion sleeve body. Detailed Implementation

[0033] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions are only used to explain the present invention and are not intended to unduly limit the present invention.

[0034] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0035] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0036] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0037] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0038] A novel electrofusion joint based on magnetic induction eddy current heating includes an electrofusion sleeve body 11, a bolt 1, a spiral coil 2, a honeycomb magnetically conductive metal mesh 9, an observation port 10, and a pipe fitting 5 to be welded. The spiral coil 2 is sleeved outside the electrofusion sleeve body 11 and is connected to an external alternating power supply 8. The observation port 10 is provided on the electrofusion sleeve body 11, extending from outside the electrofusion sleeve body 11 into its interior. The honeycomb magnetically conductive metal mesh 9 is embedded within the electrofusion sleeve body 11; the pipe fitting 5 to be welded passes through the honeycomb magnetically conductive metal mesh 9.

[0039] The honeycomb shape does not affect the flow of polyethylene after melting, and it can also make the welding temperature field of the electrofusion joint more uniform, thus improving the welding quality of the electrofusion joint.

[0040] In some embodiments: the electrofusion sleeve body 11 includes an upper electrofusion sleeve 3 and a lower electrofusion sleeve 4; the upper electrofusion sleeve 3 extends outward and is provided with an upper connecting lug, and the upper connecting lug is provided with a first threaded through hole 33; the lower electrofusion sleeve 4 extends outward and is provided with an upper connecting lug, and the lower connecting lug is provided with a second threaded through hole 41; the bolt 1 passes through the first threaded through hole 33 and the second threaded through hole 41 to fasten the upper electrofusion sleeve 3 and the lower electrofusion sleeve 4 outside the pipe fitting 5 to be welded.

[0041] In some embodiments: the outer surface of the upper electrofusion sleeve 3 is provided with a first external thread groove 32, the outer surface of the lower electrofusion sleeve 4 is provided with a second external thread groove 42, and the spiral coil 2 is wound along the first external thread groove 32 and the second external thread groove 42.

[0042] In some embodiments: the honeycomb magnetic metal mesh 9 includes an upper honeycomb magnetic metal mesh 91 and a lower honeycomb magnetic metal mesh 92; the upper honeycomb magnetic metal mesh 91 is fixedly installed inside the upper electrofusion sleeve 3; and the lower honeycomb magnetic metal mesh 92 is fixedly installed inside the lower electrofusion sleeve 4.

[0043] The honeycomb magnetic metal mesh 9 is fixed at both ends of the limiting pin; the inner wall of the upper honeycomb magnetic metal mesh 91 is provided with several third threaded through holes 911; the inner wall of the lower honeycomb conductor metal 92 is provided with several fourth threaded through holes 921; the upper honeycomb magnetic metal mesh 91 is fixedly connected to the upper electrofusion sleeve 3 by screws, third threaded through holes 911, and first threaded holes 33; the lower honeycomb magnetic metal mesh 92 is fixedly connected to the lower electrofusion sleeve 4 by screws, fourth threaded through holes 921, and second threaded holes 44.

[0044] In some embodiments, the thickness of the honeycomb magnetic metal mesh 9 ranges from 0.5 to 2.0 mm.

[0045] In some embodiments: the spiral coil 2 has 10 to 20 turns, and the pitch between turns is 5 to 10 mm.

[0046] In some embodiments, a monitoring and adjustment system is also included, which includes an infrared CCD camera 6 and a controller 7. The infrared CCD camera 6 is used to acquire temperature data and temperature images during the welding process and send the data to the controller 7. The controller is used to receive the data sent by the infrared CCD camera 6 and process the data to adjust the frequency of the alternating magnetic field generated by the spiral coil 2, thereby changing the heat generated by the honeycomb magnetic metal mesh 9.

[0047] In some embodiments, the adjustment method is as follows:

[0048] (1) Set the welding threshold;

[0049] (2) Obtain real-time temperature data and corresponding real-time temperature images during the welding process through infrared CCD camera 6;

[0050] (3) Perform image processing on the real-time temperature data and the corresponding real-time temperature image in step (2) to generate an image matrix, form a projected grayscale image and reconstruct the welding temperature field to obtain the welding temperature field, the current minimum temperature, the maximum temperature and the average temperature.

[0051] (4) Compare the result obtained in step (3) with the threshold in step (1) to obtain the temperature adjustment amount ΔT;

[0052] (5) According to the temperature adjustment amount ΔT in step (4), adjust the alternating power supply to change the output voltage frequency, thereby changing the frequency of the alternating magnetic field generated in the spiral coil, adjusting the heat generated by the magnetic eddy current effect of the honeycomb magnetic metal mesh, so as to keep the welding temperature stable in real time throughout the welding process to ensure the effective welding of the electrofusion joint.

[0053] The working process of this invention is as follows:

[0054] The first step is to fix the new type of electrofusion sleeve to the end of the pipe fitting to be welded, wind a coil in the spiral groove on the outer wall of the electrofusion sleeve, and connect the two ends of the coil to the output port of the alternating power supply.

[0055] The second step is to start the alternating power supply, infrared CCD camera and terminal processor, and set the optimal welding temperature;

[0056] The third step is to observe when the column material inside the hole has been completely ejected, at which point the welding is complete.

[0057] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A novel electric fusion joint based on magnetic induction eddy current heating characterized by: The electric melting sleeve body (11), bolt (1), spiral coil (2), honeycomb-shaped magnetic metal net (9), observation port (10), and pipe to be welded (5) are included. The spiral coil (2) is sleeved outside the electric melting sleeve body (11) and connected with the external alternating power source (8). The honeycomb-shaped magnetic metal net (9) is embedded inside the electric melting sleeve body (11). The observation port (10) is arranged on the electric melting sleeve body (11) and leads from outside the electric melting sleeve body (11) to inside the electric melting sleeve body (11). The monitoring and adjusting system is also included, which comprises an infrared CCD camera (6) and a controller (7). The infrared CCD camera (6) is used to acquire temperature data and temperature images during welding and send the data to the controller (7). The controller is used to receive the data sent by the infrared CCD camera (6) and process the data to adjust the frequency of the alternating magnetic field generated by the spiral coil (2) so as to change the heat generated by the honeycomb-shaped magnetic metal net (9).

2. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 1, wherein: The electric melting sleeve body (11) comprises an upper electric melting sleeve (3) and a lower electric melting sleeve (4). The upper electric melting sleeve (3) is externally provided with an upper connecting lug, and the upper connecting lug is provided with a first threaded through hole (33). The lower electric melting sleeve (4) is externally provided with a lower connecting lug, and the lower connecting lug is provided with a second threaded through hole (41). The bolt (1) passes through the first threaded through hole (33) and the second threaded through hole (41) to buckle the upper electric melting sleeve (3) and the lower electric melting sleeve (4) outside the pipe to be welded (5).

3. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 2, wherein: The outer surface of the upper electric melting sleeve (3) is provided with a first external threaded groove (32), and the outer surface of the lower electric melting sleeve (4) is provided with a second external threaded groove (42), and the spiral coil (2) is wound along the first external threaded groove (32) and the second external threaded groove (42).

4. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 2, wherein: The honeycomb-shaped magnetic metal net (9) comprises an upper honeycomb-shaped magnetic metal net (91) and a lower honeycomb-shaped magnetic metal net (92), the upper honeycomb-shaped magnetic metal net (91) is fixedly installed in the upper electric melting sleeve (3), and the lower honeycomb-shaped magnetic metal net (92) is fixedly installed in the lower electric melting sleeve (4).

5. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 1, wherein: The thickness of the honeycomb-shaped magnetic metal net (9) ranges from 0.5 to 2.0 mm.

6. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 1, wherein: The number of turns of the spiral coil (2) ranges from 10 to 20, and the turn-to-turn pitch ranges from 5 to 10 mm.

7. A novel magnetic induction eddy current heating based electrical fusion joint as claimed in claim 6, wherein: The monitoring and adjusting method is as follows: (1) setting a welding threshold value; (2) obtaining real-time temperature data and corresponding real-time temperature images during welding by the infrared CCD camera (6); (3) generating an image matrix by image processing the real-time temperature data and corresponding real-time temperature images in step (2), forming a projected gray scale image and reconstructing a welding temperature field to obtain the welding temperature field, the minimum, maximum, and average of the current temperature. (4) comparing the obtained result in step (3) with the threshold value in step (1) to obtain a temperature adjustment amount ΔT; (5) adjusting the alternating power supply according to the temperature adjustment amount ΔT in step (4) to change the output voltage frequency, so as to change the frequency of the alternating magnetic field generated in the spiral coil, adjust the heat generated by the honeycomb-shaped magnetically conductive metal mesh due to the magnetic induction eddy current effect, and further make the welding temperature in the whole welding process real-time stable to ensure the effective welding of the electrically fused joint.

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